Numerical Analysis and Optimization of Hydroforming Parameters of a 2024-T3 Aluminum Alloy Interface Part for Aerospace Applications

Abstract

 This study investigates the production of a 2024-T3 aluminum alloy interface component, designed for the mounting of a commercial antenna onto a helicopter tail, using the hydroforming process. Hydroforming is a widely utilized sheet metal forming technique in aerospace applications, operating on the principle of utilizing high fluid pressure to induce plastic deformation of the blank into a male or female die. Compared to conventional forming methods, it enables the production of complex geometries with superior quality. Within the scope of this work, the interface part was first designed to conform to the surfaces of both the antenna and the helicopter tail, followed by the development of the female hydroforming die geometry. The effects of critical process parameters, such as fluid pressure, blank holder force (BHF), and initial blank dimensions, on thinning and stress distribution were examined through Finite Element Analysis (FEA) based on the Forming Limit Diagram (FLD) and material hardening criteria. Through iterative simulations, the optimal process parameters required to prevent potential failure modes, such as tearing and wrinkling, were identified. The results indicate that fluid pressures reaching 50 MPa are necessary for successful forming, with a minimum achievable corner radius of 22 mm. Consequently, it is demonstrated that 2024-T3 alloy can be effectively formed into complex aerospace components using the hydroforming method.